Advanced automation is changing the way ships are built. As the industry’s most forward-looking shipyards eye full autonomy, they’re integrating digital manufacturing technologies, robotics and augmented reality to make it happen.
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It takes millions of man-hours to build a ship and that’s not changing anytime soon. What is changing, though, is how. Faced with mounting pressure to build faster, more efficiently and sustainably, shipyards are reaching the limits of what traditional production methods can do. That’s why an increasing number are turning to automation, with the ultimate goal of becoming fully autonomous shipyards, to keep pace with demand and stay competitive.
The advantages of automation and robotics
In an autonomous shipyard, production doesn’t stop. Robotics, digital twins, artificial intelligence (AI), the Industrial Internet of Things (IIoT) and augmented reality (AR) all work together within a seamless, data-driven ecosystem, fabricating and assembling pre-outfitted blocks and parts around the clock with a guaranteed high level of consistency, speed and precision.
Studies suggest that automated shipbuilding approaches can reduce engineering time by up to 30% and cut assembly time by around 20%, resulting in substantial savings across large-scale commercial and naval programs.
Automation is already transforming key stages of ship production. Welding, nesting, cutting, painting, material handling and inspections are increasingly performed by robotic systems. Robotic welders, for example, deliver consistent, high-quality seams that reduce rework and improve structural integrity. Laser welding can be up to 10 times faster than conventional methods and is proven to limit heat distortion, which is a common source of delays in shipyards. Automated spraying systems apply even paint coatings in irregular and hard-to-reach sections and, at the same time reduce labor requirements and turnaround times. Then there are robotic cranes and exoskeletons that lighten physical work for human workers.
By taking on hazardous and repetitive tasks, robotic systems make shipyards safer and more productive, freeing up skilled teams to focus on higher-value work such as integration and quality assurance.
Digital technologies powering the autonomous shipyard
The same technologies transforming aerospace and automotive production are making their way into shipbuilding and laying the foundation for the autonomous shipyard of the future.
Across the industry, shipyards are evolving into smart, connected, data-driven manufacturing environments powered by advanced technologies, including:
Digital platforms: Centralized, model-based digital platforms connect design, engineering, planning, production and logistics in one place to cover the entire product lifecycle. By replacing siloed workflows and manual, paper-based processes with digital, collaborative workflows, shipbuilders gain a clear view of every development program so they can track and coordinate engineering changes, manage resources in real time and improve production schedule reliability.
Virtual simulation: Advanced simulation solutions empower shipyards to optimize manufacturing processes and assembly sequences, balance workloads and validate design modifications before production begins. This virtual approach helps to avoid bottlenecks and rework and streamlines execution once construction is underway.
Digital twins: High-fidelity digital representations of a shipyard and all its assets provide a real-time view of operations. Integrating systems, sensors, PLC and IIoT data, digital twins give shipyards all the insights they need to track blocks and components, optimize resources dynamically and predict future maintenance needs as they move towards autonomous production.
Augmented reality: AR guides operators during pre-outfitting and assembly by projecting digital instructions directly onto physical components. Workers can see placement references, verify alignments and follow step-by-step instructions using AR glasses, tablets and cameras. This approach speeds up preparation work, reduces errors, improves traceability and supports ongoing skills development and training.
The autonomous shipyards of tomorrow are already taking shape. Understanding how to harness automation, robotics and AR is key to unlocking new levels of efficiency, reliability and sustainability at scale, and redefining what’s truly possible in modern shipbuilding.
For a more in-depth look at how these technologies are revolutionizing shipyard operations, Dassault Systèmes’ ebook “Autonomous Shipyards: Revolutionizing Production with Automation and Augmented Reality” offers practical insights and real-world case studies from leading shipyards around the globe.
